With nearly 30 years of experience in turbocharging passenger cars, Saab has
become a leader in the art of turbocharging.

The expertise and experience of Saab Automobile Powertrain is recognised by
its role as a centre of expertise within General Motors for the development of
turbocharged petrol engines.

Swedish engineers were closely involved during the conceptual design and
development of GM's new global V6 engine, ensuring turbocharged application.

As a result, Saab customers can now enjoy the combined benefits of
turbocharged power and six cylinder refinement in a purpose-built package. With
the 184 kW V6 Turbo, Aero delivers impressive pulling power. Peak torque of 350
Nm is available between 2,000 and 4,500 rpm and 90 per cent available at 1,500
rpm.

Construction

The V6 Turbo has a 60 degree vee-angle between its cylinder banks for perfect
balance and combines excellent multi-valve refinement with outstanding
performance.

The all aluminium construction provides a light and compact architecture,
well suited to its transverse, front-wheel-drive installation in the Saab 9-3
Aero. The Saab V6 Turbo is manufactured at GM Holden’s Engine Operations in Port
Melbourne.

Turbocharging

The twin-scroll, water-cooled Mitsubishi TDO4-15TK turbocharger, operates at
0.6 bar maximum boost with intercooling and an integral by-pass valve. It is
mounted centrally above the transmission and fed by both banks of cylinders.

The use of two separate inlet tracts, one for each cylinder bank, separates
the exhaust gas pulses, improving gas flow, reducing energy losses and raising
turbocharger efficiency. The turbine wheel is made from a special high-grade
steel alloy, commonly used in the turbocharged engines of world championship
rally cars, which is resistant to erosion, cracking and creeping under high
temperatures and centrifugal forces.

State of the art, and unique to this application, are the double-skin exhaust
manifolds, which are hydroformed with stainless steel liners to improve
cold-start emissions by minimising heat absorption to the manifold. Air
injection into each manifold for up to 30 seconds after a cold-start also helps
the central pre-catalyst, positioned upstream of the main catalytic converter,
to achieve 'light off' (its effective working temperature) as early as possible.

Valvetrain

The cylinder heads, each with double chain-driven overhead camshafts
operating four valves per cylinder, are of high specification aluminium and
unique to this turbocharged variant. The design ensures enhanced heat resistance
as well as minimum maintenance costs.

Also unique are pistons with hard anodized ring grooves for durability and
underskirt oil jet cooling, together with steel con-rods that are strengthened
by sinterforging, a process that involves moulding metal in a powered form. The
exhaust valves are filled with sodium to further enhance cooling. The cylinders
have cast iron liners and a bore/stoke of 89.0/74.8 mm.

Variable Cam Phasing

For improved engine breathing, variable cam phasing on the inlet side is
electronically controlled and hydraulically actuated, allowing continuously
variable adjustment through 50 degrees of crankshaft rotation. On the road, this
translates to a more flexible power delivery and better fuel economy under
different engine loads.

A die-cast aluminium oil sump is designed to increase structural stiffness
and the strong, four-bearing crankshaft is made from micro-alloy forged steel, a
specification more commonly seen in competition performance or diesel engines.

Smart engine management

The 32-bit engine management system, with software calibrated specifically
for the Saab 9-3 application, uses a torque-based engine control strategy and
direct coil-over-plug ignition with a robust engine-mounted control unit.
Ignition timing, fuel injection, turbo boost pressure, air mass measurement and
the throttle setting are all key engine functions controlled by the software.

The sophisticated control strategy is designed to deliver smooth performance
in all driving conditions. The system works with the vehicle’s transmission to
modulate torque, providing stirring performance and excellent engine response.
The system can also limit torque in low-traction conditions, helping provide
confident, surefooted driving. Variable fuel pressure further contributes to
smooth idle and driving characteristics.

Electronic throttle control

For driving comfort, control of the electronic throttle through the movement
of the accelerator pedal is programmed to be sensitive to different driving
conditions, with greater pedal movement introduced at lower vehicle speeds, such
as when manoeuvring or parking. At low engine speeds, the engine control system
also brings the turbo in quickly by momentarily opening the throttle slightly
more than requested by the driver.

Power and torque

On the road the new 9-3 Aero V6 Turbo packs a formidable punch and the driver
will immediately appreciate the smooth power delivery. Apart from the boost
gauge in the dashboard, the only clue to the presence of a turbocharger is an
uncannily effortless rate of acceleration.

Pick-up from tick-over at just 720 rpm is instant, due to the engine's
relatively large multi-cylinder capacity. Around 1,000 rpm, the turbo begins to
build an impressive wall of torque that is already in place by the time the
tachometer swings through 2,000 rpm. It endows the 9-3 Aero with a level of
performance never before seen in a Saab vehicle.

Maximum torque is generated all the way from 2,000 rpm to 4,500 rpm, with 90
per cent of this value available at an exceptionally low 1,500 rpm. Careful
programming of the engine management software means that under a full throttle
load, from take-off or low engine speeds, 90 per cent of maximum acceleration is
delivered within one second.

The zero to 100 km/h dash is accomplished in just 6.7 seconds, but in-gear
acceleration provides even more impressive evidence of this engine's outstanding
elasticity. In fourth gear, the transition from 60 to 100 km/h can be reached in
6.2 seconds and in fifth from 80 to 120 km/h in just 7.9 seconds, which places
the 9-3 Aero among the best in its class.

Twin exhaust

The fun-to-drive nature of this performance is also matched by an
exhilarating engine note that can be heard inside and outside the car. This has
been achieved by tuning the twin sport exhaust downstream of the main catalyst.
It gives the new Saab 9-3 Aero a distinctive aural character in keeping with its
position as the sporting flagship of the range.

Transmission

The engine is offered with a choice of six-speed manual or a new six-speed
automatic transmission. The close-ratio manual gearbox includes dual output
shafts to reduce transmission vibration. Together with a dual mass flywheel this
ensures smooth and refined performance.

For closer driver involvement, Saab Sentronic, a sequential manual gearshift,
is also included. When the shift lever is moved across the gate to ‘manual’
Sentronic mode, ‘up’ and ‘down’ changes can be made with full lock-up in third,
fourth, fifth or sixth gear. In the Saab you get the best of both worlds – you
can manually select gears either by the gear lever itself or using the steering
wheel controls.

Overall, the V6 Turbo generates class-leading levels of torque with a
seamless, turbine-like power delivery. It combines the inherent advantages of a
six-cylinder engine - refinement and a rapid throttle response - with the
effortless, torque-boosting properties of turbocharging.

The Holden built Saab 2.8 litre V6 Turbo engine

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